EP2473330A1 - Procédé de plaques machines avec un revêtement dur imprégné de fluoropolymère - Google Patents

Procédé de plaques machines avec un revêtement dur imprégné de fluoropolymère

Info

Publication number
EP2473330A1
EP2473330A1 EP10812741A EP10812741A EP2473330A1 EP 2473330 A1 EP2473330 A1 EP 2473330A1 EP 10812741 A EP10812741 A EP 10812741A EP 10812741 A EP10812741 A EP 10812741A EP 2473330 A1 EP2473330 A1 EP 2473330A1
Authority
EP
European Patent Office
Prior art keywords
laminate
press
coating
decor
plates
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP10812741A
Other languages
German (de)
English (en)
Other versions
EP2473330A4 (fr
Inventor
Patrick Smith
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Unilin Nordic AB
Original Assignee
Pergo Europe AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pergo Europe AB filed Critical Pergo Europe AB
Publication of EP2473330A1 publication Critical patent/EP2473330A1/fr
Publication of EP2473330A4 publication Critical patent/EP2473330A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • B30B15/06—Platens or press rams
    • B30B15/062—Press plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0046—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by constructional aspects of the apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B44C5/0476—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/18—Paper- or board-based structures for surface covering
    • D21H27/22—Structures being applied on the surface by special manufacturing processes, e.g. in presses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/26—All layers being made of paper or paperboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/12—Coating on the layer surface on paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/028—Paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2327/00—Polyvinylhalogenides
    • B32B2327/12—Polyvinylhalogenides containing fluorine
    • B32B2327/18—PTFE, i.e. polytetrafluoroethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/03—Non-macromolecular organic compounds
    • D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
    • D21H17/11—Halides
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/18—Paper- or board-based structures for surface covering
    • D21H27/22—Structures being applied on the surface by special manufacturing processes, e.g. in presses
    • D21H27/26—Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures
    • D21H27/28—Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures treated to obtain specific resistance properties, e.g. against wear or weather
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles

Definitions

  • This invention is directed to novel laminates and processes for producing the same by use of a pressing apparatus.
  • the laminates of the present invention have an abrasion resistant surface created by including a plurality of small hard particles, at least some of which are adjacent to the pressing apparatus during fabrication of the laminate.
  • Pressing apparatus used to form such laminates may be a laminate press having press plates, a press belt, or a plurality of a laminate layers may separated by press plates such that a stack of laminate products may be pressed and formed during a single press cycle.
  • the pressing apparatus applies pressure to form and consolidate the individual layers or laminae into a laminate article.
  • Abrading or polishing of the pressing surfaces, whether of the press plates, or the interleaved press plates is caused by the presence of the small hard particles. Reduction of scratching is accomplished by use of a flouro-polymer incorporated into a coating on the pressing surface.
  • the novel laminated article also comprises the same flouro- poiymer,
  • Laminate articles produced by pressing are generally well
  • Laminate articles are usually composed of a plurality of layers or laminae with are consolidated under heat and pressure in a pressing apparatus.
  • the layers may be separately impregnated with a binding agent, such as a thermosetting resin, or may alternatively be previously impregnated, dried and partially cured to the so-called B-stage to form a "prepreg" which is then fed into a press with one or more other layers of paper, or core materials, such as fiberboard (usually medium density fiberboard (MDF) or high density fiberboard (HDF)), flax, gypsum, plywood, particleboard, oriented strandboard (OSB) 1 recycled thermosetting and/or thermoplastic materials, virgin thermosetting particles secured together with a binder, synthetic or natural rubber containing layers, and mixtures thereof; and a backing or "balance" layer to prevent warping of the laminate.
  • MDF medium density fiberboard
  • HDF high density fiberboard
  • OSB oriented strandboard
  • the backing layer is also usuaSiy formed of a thermosetting resin with one or more paper layers and is conventionally in the form of a prepreg.
  • Suitable thermosetting resins include melamine-formaldehyde, phenol- formaldehyde, phenol-urea-formaldehyde and polyester resins.
  • the upper surface of the laminate may include one or more decorative layers, such as a printed or monochromatic decor paper, or the aforementioned "core" may itself be decorated, such as by printing a decorative ink directly thereon, by applying paint or lacquer layers in different patterns thereon, or by combinations of the same.
  • ⁇ -cellulose impregnated with a resin such as a thermosetting resin, e.g., a mela mine-formaldehyde resin, was placed over the abrasive particles.
  • a resin such as a thermosetting resin, e.g., a mela mine-formaldehyde resin
  • the present invention is directed to providing a process for producing laminate products including thermosetting resins.
  • the pressing surface used in the process may either take the form of press plates, which are directly attached or adjacent to the press, or a press plate which is provided in a stack of interleaved laminate materials so as to simultaneously press a plurality of laminates at the same time.
  • press plates/press plates/belts are formed of a metal, such as stainless steel with a coating of nickel and/or chrome or alloys thereof which can be impregnated with a flouro- polymer.
  • abrasion resistant surface produced by a plurality of hard particles in the laminate product.
  • Such materials can be used for floor, wall and DC ⁇ ng panels, building boards, and components of floors providing an abrasion resistant surface to provide many years of acceptable life without surface scratches,
  • FIG. 1 is a schematic view of a laminating press
  • FIG. 2 is a schematic view of a multiplate press.
  • laminates may be produced utilizing a laminating press of the type as shown in Fig.1 having an upper and lower plates 110, respectively, operated by hydraulic, pneumatic, mechanical, electrical, or other forces (not shown) to create pressure when the plates 110 are moved relative to each other.
  • the most preferred form of press is a hydraulically operated press, where the lower plate 110 is fixed and only upper plate 110 is moveabie.
  • other forms of presses can be used.
  • a plurality of laminae are inserted between plates 110 and consolidated into an article or laminate.
  • the laminae can consist of one or more layers themselves, at least to some of which a thermosetting resin has been applied, with or without previous curing into the so called B-stage and being consolidated in the press under elevated temperature and elevated pressure,
  • Fig. 1 is typical of a pressing apparatus into which is fed a plurality of laminae, at least one being a decorative paper or decor layer 122 comprising one or more layers, being a wood veneer
  • thermosetting resin and at least one base layer paper or core material 124.
  • base layers are Kraft or other paper layers
  • thermosetting resin impregnated with a thermosetting resin and as suitable core materials are various cellulosic layers such as MDF or HDF, plywood, oriented strandboard, particleboard, gypsum, flax; gypsum, thermosetting and/or thermoplastic particles bound together with an adhesive, recycled thermosetting resin particles, etc.
  • the thermosetting resin can be either coated as a liquid which is then dried; optionally cured into a B-stage; or freshly applied resin which is still wet.
  • An upper layer of the laminae would include hard particles having a Moh's hardness of at least about 5, most preferably at least about 6, and comprises particles of, for example, aluminum oxide, silicia, silicon carbide, silicon nitride, diamond, and combinations thereof.
  • These hard particles are preferably of small size, i.e., having an average particle size ranging from about 2 to about 120 microns, more preferabably about 5 to about 90 microns, most preferably about 8 to about 80 microns.
  • small hard particles have an average particle size up to 120 microns and Mori's hardness of at least about 5. These small hard particles are typically dispersed across the upper layer, for example, sprinkled on the surface or imbedded throughout the paper or resin.
  • the hard particles in proximity to the press plates 110 can be in a position to scratch or mar the surface of the plates thereby decreasing the plate life, as well as producing minor defects or gouges in the surface of the plate, thereby resulting in subsequently produced laminate having the negative reproduction or change in gloss of these surface defects in its upper surface.
  • Other laminae could include sound dampening layers of natural of synthetic foamed or unfoamed rubber, balance layers, on acoustic layer or the bottom of the laminate.
  • the laminate appear to include surface structuring of real wood, such as knot holes, graining, pits, micro-cracks and other similar surface features, as are found in real wood floors. These surface features could, for example, enhance or be "in register” with the image below, or may be random. The same is true for other types of simulated natural products, such as stone or mineral floors reproduced by laminates which have raised and/or depressed surfaces.
  • the surfaces of plates 110 are, most often, covered with a metal such as nickel and/or chrome metals or their alloys.
  • Plate 110 and/or the coating 118 on upper plate 110 might have the negative surface of wood board, such as small protrusions to simulate pits or graining in the laminate.
  • Coating 120 on lower plate 110 would not necessarily need the same degree of surface decoration, as it normally is making a bottom side of the laminate product, not normally seen in use. However, there may be surface features stippling or other structural surface features also present on the bottom of the laminate imparted by lower plate 110 coating 120 on lower plate 110.
  • the present invention coats the plate 110, typically formed of stainless steel, with a nickel and/or chrome coating 118.
  • the metal coating will be impregnated with a flouro-polymer, such as a fluoro-carbon, CF 3 (CF 2 Jn-CF 3 , such as a polytetrafluoroethylene polymer having a weight average molecular weight of 400,000-9,000,000; such materials are
  • the present invention can provide a pressing surface that not only has a much better release from the laminate surface including those surfaces containing protrusions and depressions, but also that the press plate can be utilized in more pressing cycles without the need to repair or replace the plate surface.
  • the present invention also makes it possible to omit this "overlay” layer and have the wear resistant hard particles applied directly to the top surface of uppermost laminae without any overlay paper. Such a process produces a product which is much more desirable because the presence of the overiay can obscure, even if in a minor degree, the decor on the decor layer. It is also considered within the scope of the invention to incorporate at least some of the abrasion resistant particles into an uppermost surface or layer of the core material itself.
  • FIG. 1 there is shown a press in which upper and lower press plates 110 are provided with a nickel and/or chrome coating 118, 120 respectively, which coatings 118, 120 are
  • an impregnated decor layer 122 comprising a decor paper having hard particles, applied directly thereon while the thermosetting resin is stilt wet, is laminated to a core 124 formed of prepreg Kraft paper layers and balance layer 126 by closing press plates 110 thereby applying elevated pressure while under elevated heat conditions to bond layers 122, 124 and 126 into a laminate.
  • layers 124 and 126 are prepreg paper core and balance layers, they may readily be substituted by other materials such as the core materials, previously described such as IVIDF 1 HDF, and/or particleboard, gypsum, plywood, OSB, flaxboard, etc.
  • Decor paper 122 may be impregnated with a thermosetting resin which has been dried or even partially cured to the so-called B-stage or may still be wet.
  • layer 124 may be a prepreg of the so called B-stage cure resin impregnated paper, or other core materiais as described.
  • Adhesive (not shown) may inserted between any of layers 122 , 124 and 126, especialiy when such layers are of the partially B-stage cured type.
  • the resulting laminate products are highly abrasion resistant and may be utilized in high wear areas such as floor board, planks, tiles, etc.
  • edges of the laminate may be provided with joining elements, such as grooves and/or tenons or may be employed with separate joining pieces to join individual boards into a unitary floor structure.
  • Laminate floors are, most typically, not attached to any substructure, such as a subfloor, but are called “floating floors” as they are free to move independently of the substructure.
  • the joining elements therefore lock the individual laminate boards together, not only to prevent separation in the vertical direction, but also horizontally along the edge of the joint between boards. This can be achieved by any of the known locking systems in the art said as that found in U.S. Patent 5,706,621 and its reissue, US RE 39,439; U.S. Patents 6,006,486; 6,101 ,778; and 6,397,547; ali incorporated herein by reference.
  • blower (not shown) to apply an air stream between the pressed laminate and the press plate after pressing to further reduce any adhesion.
  • This air should be heated to a temperature close to the temperature of the plates and/or heated laminate to reduce the risk of uneven cooling.
  • the expected better plate life (more press cycles before refinishing), potentially fewer plate cleanings and faster press times, ail are expected to support lower product cost and better equipment utilization.
  • a distinct advantage of the invention is realized when the "true liquid overlay" products are produced, where the wear resistant particles are applied directly to the top of the decor without any overlay paper.
  • U.S. Patents 4,940,503 and 6,106,654 used overly papers as a layer over the abrasive particles and the press surface, but as reported in U.S. Patent 6,106,654, scratching of the press plates was still experienced. The present process would permit omission of the overlay sheet, yet still be expected to extend press plate life due to reduced scratching.
  • Fig. 2 is similar to the pressing cycle of Fig. 1 except therein a press plates 11 (of which there could be any number) is provided between various layers, forming the laminate such as overlay sheet 14, decor sheet 13 having a covering of smal! hard particles, core layer 12 such that a plurality of separate laminate products can be produced in a single pressing cycle.
  • the press plate 11 (similar to upper and lower press plates 15) can also be provided on at least one side with a metal or metallic alloy coating 10, such as a nickel or chrome coating which has been impregnated with the flouro-polymer according to the present invention, to achieve the advantage achieved with the single product production cycle discussed in Fig. 1.
  • a roll of overlay paper of ⁇ -ceilouse with a surface weight of 40 g/m 2 can be impregnated with a solution of melamine-formaldehyde resin to a resin content of 70% by weight calculated on dry impregnated paper.
  • the impregnated paper can be fed continuously into a heating oven where the solvent can be evaporated.
  • the resin can be partially cured to a so called B-stage.
  • a product that can be obtained will be caSied prepreg.
  • a roil of decor paper i.e., a paper that can have print to form a surface decoration, with a surface weight of 80g/m 2 can be treated in the same way as the overlay paper.
  • the resin content can be 40% by weight calculated on dry impregnated paper.
  • a roll of decor paper with a surface weight of 170g/m 2 can also be treated in the same way, with the exception that a resin
  • phenol-formaldehyde resin instead of melamine- formaldehyde resin
  • the resin content can be 30% calculated on dry impregnated paper.
  • Three of the above prepreg sheets can be impregnated with phenol-formaldehyde resin (to create a core paper), one decor paper and an overlay paper can be placed between two press plates which can be treated according to the present invention. The sheets can be pressed at a pressure of 90kp/cm 2 at a temperature of 145 0 C to form a homogenous
  • the press plates are expected to exhibit no adhesion of the thermosetting resin upon opening. Analysis of the resulting laminate is expected to show that some of the fiuoro- poiymer which could be have been impregnated into the coating on the press piates would migrate into the laminate.
  • Example 1 A process similar to Example 1 can be practiced except that the overiay paper of ⁇ -cellulose can be omitted and the hard particles can be placed directly on a wet resin decor paper before the press cycle so as to be in contact with a press plate which could be treated according to the present invention.
  • a laminate article is expected to show migration of the fluoro-polymer into the laminate products and improved lubricity of press plates which can be treated according to the invention are expected to permit an extended use of the press plates before cleaning and/or refurbishing.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un procédé de production d'articles stratifiés, lequel procédé comprend le revêtement ou le placage des surfaces de presse, de plaques ou de plaques de presse intercalées, avec un revêtement dur imprégné de fluoropolymère. Des revêtements typiques qui peuvent être utilisés avec le fluoropolymère comprennent du nickel et du chrome, leurs combinaisons et des alliages de ceux-ci. Les avantages de l'invention sont prévus pour comprendre une meilleure durée de vie de plaque, moins de nettoyages de plaque, de courte durée de pressage tout en supportant un coût de production inférieur et une meilleure utilisation de l'équipement. Par ailleurs, les produits stratifiés comprennent un fluoropolymère comme partie du produit stratifié. Le procédé permet l'omission de ce que l'on appelle la couche de « recouvrement », typiquement une couche d' α-cellulose, qui recouvre des particules dures dans la surface supérieure du stratifié tout en fournissant une durée de vie accrue de la surface de pressage.
EP10812741A 2009-08-31 2010-08-31 Procédé de plaques machines avec un revêtement dur imprégné de fluoropolymère Withdrawn EP2473330A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12/551,091 US20110052905A1 (en) 2009-08-31 2009-08-31 Process of providing press plates with a flouro-polymer impregnated hard coating
PCT/US2010/047267 WO2011026082A1 (fr) 2009-08-31 2010-08-31 Procédé de plaques machines avec un revêtement dur imprégné de fluoropolymère

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EP2473330A4 EP2473330A4 (fr) 2013-02-20

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EP (1) EP2473330A4 (fr)
KR (1) KR20120066645A (fr)
CN (1) CN102574315A (fr)
BR (1) BR112012004607A2 (fr)
RU (1) RU2012110769A (fr)
WO (1) WO2011026082A1 (fr)

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CN102574315A (zh) 2012-07-11
RU2012110769A (ru) 2013-10-10
WO2011026082A1 (fr) 2011-03-03
BR112012004607A2 (pt) 2016-08-02
KR20120066645A (ko) 2012-06-22
EP2473330A4 (fr) 2013-02-20
US20110052905A1 (en) 2011-03-03

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